PowaCycle Cambridge User manual

ElectricallyAssistedPedalCycles
AssemblyInstructions
Version 5 – 19 Dec 2005

2
Introduction
ThankyouforbuyingaPowaCycleCambridge/Oxford
electricbike.Wehopeitbringsyoumanyhoursof
enjoyment.
Forsafeandcompactshipping,wehavedespatchedyour
PowaCycleCambridge/Oxfordpartassembled.It
thereforerequiressomeassemblyworkbeforeyoucan
beginriding.
Pleasefollowtheseinstructionscarefully.Ifyoudonot
feelconfidenttoassemblethebikeyourself,we
recommendyouvisityourlocalcyclestorefor
professionalhelpandadvice.Someassemblydetailsmay
varyduetotherecentproductimprovements.
Contents
Beforeassembly,pleasecheckthatyouhaveallthepartsbelow:
FrontWheel BatteryCharger Pedals
2 xNutcoversforfrontforks MainCycleFrame

3
AssemblyInstructions
ChargetheBattery
BeforeassemblingyourPowaCycle,youshouldchargethebattery.
Thiswillallowyoutotesttheelectricalconnectionsduringassembly.
Itmaytakeupto6hourstofullychargethebattery.Whencharged,
theLEDturnsfromredtogreen.Pleasenote,thebatterywill
deteriorateifitisleftuncharged.
Aleveratthebaseofthesaddlecolumn
releasesthesaddle,allowingthesaddletobe
liftedoutofthebikeframe,thismakesthe
batteryaccessible.
LiftthehandleonthebatteryandSlidethe
batteryfromthebasehousing. Youwill
notice2piecesofplasticcoveringthecontact
terminals,removethesefromthebike.
Chargethebatteryawayfromwateror
combustiblematerial.
Connecttheroundendedchargerplugtothe
batterysocket.Plugthechargerintothe
mainssupplyandswitchitonattheplug.

4
FittingtheHandlebars
Thehandlebarsarealreadyattachedtothe
frameviacables.
Theynowneedtobeinsertedintotheframe
asshown.
Alignthehandlebars90degreestotheforks.
Finally,useanAllenkeysuppliedor
hexagonaltooltotightenthehandlebarsin
place.
NOTE:Werecommendthatyoumakeafinal
adjustmentofthehandlebarsoncethebikeisfully
assembled.

5
FittingtheWheel
Removetheblackplasticfrontfork
protectors,whicharepartoftheprotective
packingmaterial.
Werecommendthatyouturnthebicycle
upsidedown,restingitonthehandlebars
andsaddle.
Note:Wesuggestyouremovethebattery,tomakethe
bikelighter,beforeturningitupsidedown.Also,you
mayneedtoadjustthesaddletomakeitmorestable.
Placethewheelbetweentheforks.
Thenfastenthenutsandwasherstoeach
sideofthewheelspindle,tighteningthem
evenly.
Useaspannersuppliedtosecurethenuts
firmlytotheforks.
Thewheelneedstospinfreely,soavoidover
tightening.

6
BrakeAssembly
Withthecycleupsidedown,ensurethatthe
brakeblockshaveclearancefrom,andare
paralleltothewheelrims.UseanAllenkey
orhexagonaltooltoadjustandsecurethe
blocks
Placethebrakecableinthebrassfitting
(arrowed).
Ontheoppositesideofthewheel,anutis
fixedtothebrakemechanism,holdingthe
wirecable.Loosenthisnuttoallowyouto
pullthecablethroughandtakeupanyslack.
Thenretightenthenut.Checkthatthe
wheelspinsfreelyandthebrakeoperates
effectivelywhenapplied.
Fineadjustmentstothebraketensionscan
bemadeviaadjustmentcontrolslocatedat
thejunctionofthebrakeleverandcable.
FittingthePedals
PedalsaremarkedLandR,fortheleftand
righthandsideofthebicyclewhenitis
facingforward.Screweachpedalintothe
appropriatepedalshaftbyhand,andthen
tightenwithaspannertosecure.
Thepedalshaveareversethreadand
thereforeneedtobescrewedinbackwards.

7
CompletedPowaCycleCambridge/Oxford
Finally…
Beforemountingyourcycletoride,remembertocheckthat:
· thebatteryisfullycharged.
· thetyresareinflatedtothecorrectpressure.
· thebrakesareoperatingeffectively.
· thehandlebarsarecorrectlyadjustedandsecure
· theseatisatthecorrectheightfortheuser
· thelightsareworking
· allnutsandboltsaresecure(includingpreassembledones).

8
OperationoftheCambridge/Oxford
PowaCycle
Overview
ThePowaCycleCambridge/Oxfordisanelectricallyassistedbicycle
thatoperatesasastandardbicycle,withtheassistanceofamotor
andbattery.Thepowerprovidedsupportstherider’sownefforts,
givingincreasedperformancewithlesseffort.
BatteryCharging,Care&Safety
Careofthebatteryisvitaltomaximiseitslongtermperformance.
· Thebatterymustberemovedfromthebikeforcharging.
· RegularUse–Ifyouarecommutingsignificantdistances,itis
advisabletorechargethebatterybeforethereturnjourney.
· OccasionalUse–Rechargethebatteryatleastonceaweek,
evenifthecycleisunused.
· Alwaysrechargethebatteryafteruse.
· Alwayschargethebatteryindoors.
· Keepthebatteryawayfromwater,topreventshocksorshorting.
Whenattachedtothebicycle,itissafetooperateinwetconditions.
· Donotcoverthebatteryorcharger.
· Donotleavethebatterypermanentlychargingfromthemainssupply.
· Onlyusethechargerprovidedtochargethebattery.
· Donotusethebatterytopoweranythingotherthanthe
PowaCycleforwhichitwaspurchased.
· Donotdisassembleormodifythebattery.
· Donotexposethebatterytofireorextremetemperatures.
· Donotshortcircuitthebattery.
· Donotallowimpactorforceagainstthebatterypack.
· Disposeofthebatteryinadedicatedwastefacility.

9
AdditionalLights
Asanadditionalsafetyfeature,werecommendthatnightusers
purchaseindependentfrontandrearlightsthatareNOTpowered
fromthecyclebattery.Afteralongjourney,thereisariskthatthe
cyclebatterycouldbedepleted,solightsrelyingonthecyclebattery
couldstopworking.
Tyres
· Checkthetyresregularlytoensurethatthecorrectpressuresare
maintained(pressurerangesareshownonthesidesofthetyres).
· Donotoverinflatethetyres.
· Therearedifferenttypesofpumpsavailableforcycles.Askyour
localcycleshopfortheonebestsuitedtoyourneeds(donotusea
garageforecourtairhosetoinflateyourtyres).
Brakes
· Makesureyourbrakesareadjustedcorrectlyatalltimes.
· Adjustmentcanbemadeatthewheelrim/brakemechanismwith
tools.Finetuningofthebrakescanbemadeviaadjustabletwist
screwsthatarelocatedatthejoinofthebrakelevertothecable.
· Replacethebrakeblockswhenworn.
Power
Switchonthepowerbypressingtheswitchonthebattery.The
Cambridge/Oxfordcanbeoperatedasa“pedelec”.Thismeansthat,
assoonastheriderbeginstopedal,themotorsuppliesenergyto
supportthecyclist’sefforts.Iftheriderpreferstocyclewithoutthe
assistanceofthemotor,heorsheshouldturnthepoweroff.
Throttle
Inordertousethethrottlepower,theredbuttononthehandlebar
mustbepressed(thisactivatesthethrottle)andthenthethrottle
(locatedontherighthandlebar)canbeused.

10
GearsandBicycleChain
Changethroughthegearsoneatatimeandonlywhenthebicycleis
beingpedalled.Tomaintainperformance,ensurethatallthe
mechanicalpartsofthegearsarelightlyoiled(avoidgettingoil
depositsonthewheelrims).Ifthechainmechanismbecomes
dislodged,turnthepedalsforwardgentlytoengageit.Ifthechain
becomescompletelydislodged,reengageitonthesmallestgearcog.
Saddle
Formaximumcomfortensurethatthesaddleisbothcorrectly
adjustedandsecure.Oncesetupcorrectly,theheightofthesaddle
canbeadjustedwithouttools.Loosentheleveratthetopofthe
framebelowthesaddletoraiseorlowerthesaddle.Oncethesaddle
isattherequiredheight,secureitbytighteningthelever.Tightenor
loosenthenutontheleverifrequired.
UserSafety
CycleHelmets
Althoughthereisnolegalrequirementtowearacyclehelmet,we
recommendthatyoudosoforyoursafety.Wearingacyclehelmet
hasbeenproventoreducethelikelihoodofheadinjuries.
ProfessionalMaintenance
Werecommendyouhaveyourcycleservicedbyaprofessionalcycle
engineeratleastonceayeartoensureongoingsafeperformance.If
youareunsureastohowtocarryoutanassemblyprocedureor
adjustment,werecommendthatyouconsultyourlocalcycleshop.
Troubleshooting
1–Brakesnotworkingeffectively
Checkthedistancebetweenthebrakeblocksandthewheelrim.
Checkthattheblocksareparallelwiththewheelrim.
Checkforanywearonthebrakeblocks
Finetuningtothebrakescanbeperformedbytheadjusters
betweenthebrakeleveronthehandlebarsandthebrakecable.
Majoradjustmentsaremadeatthebrakeblocksandyouwill
needtheappropriatetools.Seebrakeassemblyinstructions.